<td width="243">Gives out light to the Light Dome and the Night Light.</td>

<td width="243">Gives out light to the Light Dome and the Night Light.</td>

<td width="173">Glass</td>

<td width="173">Glass</td>

−

<td width="150">Soldring</td>

+

<td width="150">Soldering</td>

+

<td width="99">[[Media:light_bulb.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 750:

Line 782:

<td width="173">Steel</td>

<td width="173">Steel</td>

<td width="150">Coiling</td>

<td width="150">Coiling</td>

+

<td width="99">[[Media:spring_connector.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 758:

Line 791:

<td width="173">Plastic</td>

<td width="173">Plastic</td>

<td width="150">Injection Molding</td>

<td width="150">Injection Molding</td>

+

<td width="99">[[Media:small_bracket_holder.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 766:

Line 800:

<td width="173">Steel</td>

<td width="173">Steel</td>

<td>Machining</td>

<td>Machining</td>

+

<td width="99">[[Media:screw3-8.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 774:

Line 809:

<td width="173">Steel</td>

<td width="173">Steel</td>

<td>Machining</td>

<td>Machining</td>

+

<td width="99">[[Media:screw3-8.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 782:

Line 818:

<td width="173">Steel</td>

<td width="173">Steel</td>

<td>Machining</td>

<td>Machining</td>

+

<td width="99">[[Media:washer_screw.JPG]]</td>

</tr>

</tr>

</table>

</table>

Line 791:

Line 828:

<center>

<center>

<table border="1" cellpadding="0" cellspacing="0">

<table border="1" cellpadding="0" cellspacing="0">

−

<tr align="center">

+

<tr align="center" bgcolor="#CCCCCC">

<td>'''Part #'''</td>

<td>'''Part #'''</td>

<td>'''Part Name'''</td>

<td>'''Part Name'''</td>

Line 807:

Line 844:

<td width="148">Plastic</td>

<td width="148">Plastic</td>

<td>Injection Molding</td>

<td>Injection Molding</td>

−

<td width="99">[[Media:Group2.jpg]]</td>

+

<td width="99">[[Media:Front_base_cover.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 816:

Line 853:

<td width="148">Plastic</td>

<td width="148">Plastic</td>

<td>Injection Molding</td>

<td>Injection Molding</td>

+

<td width="99">[[Media:Back_base_cover.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 824:

Line 862:

<td width="148">Plastic</td>

<td width="148">Plastic</td>

<td>Injection Molding</td>

<td>Injection Molding</td>

+

<td width="99">[[Media:Blue_ring.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 832:

Line 871:

<td width="148">Plastic</td>

<td width="148">Plastic</td>

<td>Injection Molding</td>

<td>Injection Molding</td>

+

<td width="99">[[Media:Plastic_decoration.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 840:

Line 880:

<td width="148">Plastic</td>

<td width="148">Plastic</td>

<td>Injection Molding</td>

<td>Injection Molding</td>

+

<td width="99">[[Media:Battery_base_cover.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 848:

Line 889:

<td width="148">Steel</td>

<td width="148">Steel</td>

<td width="197">Coiling</td>

<td width="197">Coiling</td>

+

<td width="99">[[Media:Spring_connector.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 856:

Line 898:

<td width="148">Steel</td>

<td width="148">Steel</td>

<td>Machining</td>

<td>Machining</td>

+

<td width="99">[[Media:Screw3-8.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 864:

Line 907:

<td width="148">Steel</td>

<td width="148">Steel</td>

<td>Machining</td>

<td>Machining</td>

+

<td width="99">[[Media:Long_screw.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 872:

Line 916:

<td width="148">Steel</td>

<td width="148">Steel</td>

<td>Machining</td>

<td>Machining</td>

−

<td width="99">[[Media:Group2.jpg]]</td>

+

<td width="99">[[Media:Screw3-8.JPG]]</td>

</tr>

</tr>

<tr align="center">

<tr align="center">

Line 881:

Line 925:

<td width="148">Plastic</td>

<td width="148">Plastic</td>

<td>Injection Molding</td>

<td>Injection Molding</td>

−

<td width="99">[[Media:Group2.jpg]]</td>

+

<td width="99">[[Media:Project2arm.JPG]]</td>

</tr>

</tr>

</table>

</table>

</center>

</center>

−

<h5><u>**NOTE:</u> All the images of these steps in the table above are in the appendix</h5>

<br /><br />

<br /><br />

Line 893:

Line 936:

<i>'''Why were Different materials selected for different Components?'''</i>

<i>'''Why were Different materials selected for different Components?'''</i>

−

<p>Most of the components inside the product was made out of plastic .The housing of the< hub, base and aim was much harder and stable. It seems to be PVC. Plastic was chosen because. It is cheap, available easily and makes the products weight lighter.</p>

+

<p>Most of the components inside the product was made out of plastic .The housing of the< hub, base and aim was much harder and stable. It seems to be PVC. Plastic was chosen because. It is cheap, available easily and makes the products weight lighter. </p>

<i>'''What forces are applied to the components?'''</i>

<i>'''What forces are applied to the components?'''</i>

−

<p>In my product there is a gravitational force acting downward on the hub due to its weight the force is supported by the arm and the base.</p>

+

<p>In my product there is a gravitational force acting downward on the hub due to its weight the force is supported by the arm and the base. </p>

<p>The prevalence of plastic material in the Mobile toy makes the process much easier and cost effective. There were many places in which pieces snapped into places, which is much easier to accomplish with plastic components than it is with metal. This also made the assembly process of the product much quicker.

+

<p>The prevalence of plastic material in the Mobile toy makes the process much easier and cost effective. There were many places in which pieces snapped into places, which is much easier to accomplish with plastic components than it is with metal. This also made the assembly process of the product much quicker.</p>

<i>'''Does the shape affect the manufacturing process?'''</i>

<i>'''Does the shape affect the manufacturing process?'''</i>

−

<p>Injection molding was used for all of the plastic components, such as gears, clutch plates, hub, base, arm etc. because of their complicated shapes and for a better finish with a precise configuration.</p>

+

<p>Injection molding was used for all of the plastic components, such as gears, clutch plates, hub, base, arm etc. because of their complicated shapes and for a better finish with a precise configuration.</p>

<i>'''Why was each manufacturing process chosen for that component?'''</i>

<i>'''Why was each manufacturing process chosen for that component?'''</i>

<p>Every component has a distinct shape that allows them to fulfill their purpose .All the edges in the product are rounded, so that the child won’t get hurt. Some of them screws are washer headed because the spoke hole was little wider than the hub hole, where it was attached.</p>

+

<p>Every component has a distinct shape that allows them to fulfill their purpose .All the edges in the product are rounded, so that the child won’t get hurt. Some of them screws are washer headed because the spoke hole was little wider than the hub hole, where it was attached. </p>

<i>'''Is the component functional, cosmetic or, a combination of two?'''</i>

<i>'''Is the component functional, cosmetic or, a combination of two?'''</i>

−

<p>There are few components used in our product which are cosmetic, such as the plastic decoration in front of the base. There are some components which are cosmetic as well as functional such as the decorative mold placed inside the light dome which is connected to the clutch plate. It projects the decorations made on the mold on the room’s roof when the product is functional.</p>

+

<p>There are few components used in our product which are cosmetic, such as the plastic decoration in front of the base. There are some components which are cosmetic as well as functional such as the decorative mold placed inside the light dome which is connected to the clutch plate. It projects the decorations made on the mold on the room’s roof when the product is functional. </p>

<i>'''Why do you think the manufacturing process was chosen for a given component? '''</i>

<i>'''Why do you think the manufacturing process was chosen for a given component? '''</i>

−

<p>To make the product cost efficient, produce it in a large quantities, little waste of material and for a better finish with in the given time.</p>

+

<p>To make the product cost efficient, produce it in a large quantities, little waste of material and for a better finish with in the given time. </p>

Line 942:

Line 985:

1. Solid component made up of one material with a simple shape for example pulley, gear, and clutch plates.<br />

1. Solid component made up of one material with a simple shape for example pulley, gear, and clutch plates.<br />

−

2. Components made up of one material with a complex shape for example base, hub housing etc<br />

+

2. Components made up of one material with a complex shape for example base, hub housing etc<br />

3. Components made up of two different materials example springs<br />

3. Components made up of two different materials example springs<br />

Line 949:

Line 992:

5. Electric Components such as circuit boards and motor<br />

5. Electric Components such as circuit boards and motor<br />

+

</p><br />

+

+

<h3><u>'''Design Revisions'''</u></h3><br />

+

+

• According to the users the crib adapter doesn’t fit in all the cribs, so we can make a new interchangeable crib adapter which can fit in all cribs.<br />

+

• We can also add some more additional themes to this product such as animals, angles etc., which gives user a wide range of selection.<br />

+

• Adding musical button feature at base of the product, which makes different sound (related to the theme) every time when the buttons are pressed. This will add little bit more functionality &nbsp;&nbsp;&nbsp;to the base as well as the whole products.<br />

6. Gear three is a idler it transmits no power to its shaft. Therefore, the tangential reaction of gear four and three is equal to Wt (transmitted load, lbf).<br /> <br />

+

+

<p> '''''Diagram:'''''</p>

+

+

+

<p>'''''Governing Equations:'''''</p>

+

+

To calculate pitch diameters: <br />

+

D = (N2)*(M) <br />

+

Transmitted Load: <br />

+

Wt = (60,000*P) / (pi)*(D2)*(n) <br /> <br />

+

+

<p> '''''Calculation:''''' </p>

+

+

<p> Pitch diameters of gears 2 and 3 are:</p>

+

D2 = N2*M <br />

+

D2 = (20)*(2.5)<br />

+

'''D2 = 50 mm'''<br />

+

D3 =N3*M<br />

+

D3 = (50)*(2.5)<br />

+

'''D3 = 125 mm'''<br />

+

+

<p>Transmitted load will be: </p> <br />

+

Wt = ( 60,000*P ) / ( pi* D2 * n )<br />

+

Wt = (60,000)*(5) / (3.14)*(50)*(10)<br />

+

Therefore, '''Wt = 191 N'''<br /> <br />

+

+

<p>Tangential force of gear 2 and 3:</p> <br />

+

'''Ft23 = 191 N''' <br />

+

Fr23 = ( Ft23 ) * (tan 20) <br />

+

Fr23 = (191) * (tan 20)<br />

+

'''Fr23 = 69.5 N'''<br />

+

F23 = ( Ft23 ) / (cos 20)<br />

+

F23 = (191) / (cos 20)<br />

+

'''F23 = 203.3 N''' <br /> <br />

+

+

<p> ''Since, gear 3 is an idler it transmits no power and so the tangential reaction of gear 4 and 3 is equal to Wt.''</p>

+

+

'''Ft43 = 191 N''' <br />

+

'''Fr43 = 69.5 N''' <br />

+

'''F43 = 203 N''' <br /> <br />

+

+

<p> Reactions in x and y direction: </p>

+

Fxb3 = - (- Ft23 + Fr43 )<br />

+

Fxb3 = - (- 191 + 69.5)<br />

+

'''Fxb3 = 121.5 N'''<br />

+

Fyb3 = - (Fr23 + Ft43)<br />

+

Fyb3 = - (69.5 – 191)<br />

+

'''Fyb3 = 121.5 N'''<br /> <br />

+

+

<p>Resultant Reaction is:</p>

+

Fb3 = √ (121.5)2 + (121.5)2 <br />

+

'''Fb3 = 171.8 N''' <br /> <br />

+

+

+

<h3><u>'''Solid Model'''</u></h3><br />

+

+

[[Image:Group2Gear.jpg]]

+

+

+

+

+

+

+

+

<br /><br />

+

+

<h1>'''''Gate # 4: Critical Project Review'''''</h1>

+

+

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;The critical project review is to provide a final review of the Ocean Mobile and its components before final submission of the project .It also provides a step by step procedure for reassembling the ocean wonder mobile .Later in this section we will also discuss the differences between the two procedures (disassembly and reassembly).We will also discuss how well the product works after reassembly, if it doesn’t work then what went wrong and how the problem can be fixed.</p>

+

+

<h3><u>Product Reassembly Plan</u></h3>

+

+

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;The reassembly of the Oceanic wonder mobile took two hours approximately .Each step required to reassemble the product is detailed below:</p>

+

+

<h3><u>Reassembly Procedure:</u></h3>

+

+

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;'''''Scale for ease of assembly:''''' All values given in comparison to all of the other steps of putting this mobile toy together. This is with a “1” being a simple task such as screwing something together and a “5” being reassembling a piece that is breakable and not easy to put together without care.</p>

+

+

+

<center>

+

+

<table border="1" cellpadding="0" cellspacing="0">

+

<tr align="center" bgcolor="#CCCCCC">

+

<td>'''Step#'''</td>

+

<td>'''Process'''</td>

+

<td>'''Difficulty Level'''</td>

+

</tr>

+

<tr align="center">

+

<td>1</td>

+

<td>Put the screw back to the hub base to attach the third gear of the gear train. A small thick gear is attached to the outer bottom of the hub cover and the third cover inside the hub cover.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>2</td>

+

<td> Screw in two screws to reassemble the hub base to the bottom hub light cover.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>3</td>

+

<td> Reassembled the second gear to the gear train, which is then attached to base of the hub.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>4</td>

+

<td> Reassembled the first gear to the gear train which is then attached to the base of the hub.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>5</td>

+

<td> Put back the motor into the hub base.</td>

+

<td>2</td>

+

</tr>

+

<tr align="center">

+

<td>6</td>

+

<td> Put back the motor bushing so that it is attached to the motor cover / board.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>7</td>

+

<td> Put back the motor cover back on the hub.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>8</td>

+

<td>Attach the small gear which connects to the gear train located under the motor cover.</td>

+

<td>2</td>

+

</tr>

+

<tr align="center">

+

<td>9</td>

+

<td> Put back the big pulley on top of the motor cover and connect to the gear train</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>10</td>

+

<td>Connect the big pulley to the small pulley attached on top of the motor with the help of a rubber belt.</td>

+

<td>4</td>

+

</tr>

+

<tr align="center">

+

<td>11</td>

+

<td> Reassembled the circuit board and the buttons back on the hub base.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>12</td>

+

<td> Put the speaker back in to the slot made in the hub case.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>13</td>

+

<td>Screw the speaker cover back to the hub base.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>14</td>

+

<td>Put the power supply wires/spring connections back to their position on the hub.</td>

+

<td>3</td>

+

</tr>

+

<tr align="center">

+

<td>15</td>

+

<td> Reassemble the socket back on to the hub machine cover.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>16</td>

+

<td> Screw back the circuit board back on the hub.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>17</td>

+

<td> Put back the design molding inside the light cover.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>18</td>

+

<td> Attach the clutch plate back at the bottom of the light cover</td>

+

<td>2</td>

+

</tr>

+

<tr align="center">

+

<td>19</td>

+

<td> Reassembled the light cover back on the hub</td>

+

<td>2</td>

+

</tr>

+

<tr align="center">

+

<td>20</td>

+

<td> Put the screws back into the bottom of the hub, which helped in reconnecting the top cover of the hub, the buttons and the top light cover of the hub.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>21</td>

+

<td> Attached the three soft toy spokes back together with help of the screws</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>22</td>

+

<td> Put back the plastic decoration back on to the front side of the base.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>23</td>

+

<td> Attached the blue ring in front of the base with the help of five reasons.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>24</td>

+

<td> Put back the casing of the base back into the front base casing.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>25</td>

+

<td> Install the four d-size batteries to the base.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>26</td>

+

<td> Screw the battery cover back on the base.</td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>27</td>

+

<td> Attach the base to the arm and connect it with a screw </td>

+

<td>1</td>

+

</tr>

+

<tr align="center">

+

<td>28</td>

+

<td> Attach the arm to the hub(snap socket)</td>

+

<td>1</td>

+

</tr>

+

</table>

+

</center>

+

+

<br />

+

+

<h3><i>Tools required reassembling the product:</i></h3>

+

+

<p>

+

1. 5/8th philiphead screw driver.<br />

+

2. 3/8th philiphead screw driver.<br />

+

3. Long nose plier.<br />

+

4. Small pick.<br />

</p>

</p>

+

+

<i>'''Does your product run the same as it did before you disassemble it?'''</i>

+

+

<p>Yes, The Oceanic wonder Mobile functions the same as it was before it was disassembled .The product was picked up in perfect working condition; It is still working the same way with no problems.</p>

+

+

<i>'''What were the differences between the disassembly/reassembly of the product?'''</i>

+

+

<p>The process of assembly is almost the reverse of the disassembly. The only difference in assembly is that the aim connects to the hub and the base at the last, whereas during disassembly. I was not able to separate to separate the hub from the arm as it was snapped into the hub. Same set of tools were used again to reassemble the whole product.</p>

+

+

<i>'''Additional recommendations:'''</i>

+

+

<p>Additional feature for tor the Ocean Wonder Mobile would be to add a rechargeable battery to the base instead of 4-D alkaline batteries .The disadvantage of this will be a little hike in the price but it would be out-weighted by increase in the life of the product and the cost of spending money on the four D alkaline batteries will be gone. </p>

GATE - 1: Request for Proposal

Work Proposal

Our product for the project is a Fisher Price Children’s toy – Musical Mobile. This toy has a mechanical motor connected at the top, which rotates slowly with the help of two batteries. This product is completely manufactured out of plastic and has more than 10 parts. But, there are 5 main parts which makes this product complex.

The five main parts are:

1. The motor
2. The hinge (in the middle of the stem to bend the products).
3. The remote (also operates with the help of the AA-batteries).
4. The plastic casing/housing.
5. Build-in musical system.

1. We will start with taking the housing apart, a 3/16 and 1/8 philiphead screw driver and pick will be used. There are more than 10 visible screws on the housing.
2. After the screws are removed the housing can be carefully pried open using the pick and a screwdriver, while doing this we will remove the installed level and disconnect the motor.
3. The motor wires will be disconnected from the base. Once we finish separating the motor wire from the battery slots or motor, we will move on to disassembling the main components of the toy.
4. We will then disassemble the hinge, which is connected to the two stems.
5. After that we will move on to the top part where the rotational motor and the music mechanism is installed.
6. For the top part, we first have to take the top case cover/housing apart to disconnect the power button wires connected to the motor and the wires connected to the music mechanism.
7. After removing the housing we have can take apart the motor and the music mechanism.
8. Removing apart the motor and the music mechanism, now we can take apart the housing which is attached to the motor. We have to be very careful in this step, as the motor is really delicate and can break.

Working as a team disassembling this product would probably take us around 4 hours. We have discussed the disassembly procedure and think that we won’t face any major hurdles, if we follow the procedure step by step. The only problem we might face will be the top part of the toy where the rotational motor mechanism is installed.

Our group is well balanced. There are no present weaknesses in our group skills to disassemble the Fisher Price Children’s toy – Musical Mobile. Each member has been assigned a task, and assigned to be in charge of different parts in this project. Everyone in our group is excited and willing to take up this challenge as a group.

Management Proposal

Main Contacts for Group 2

To learn how to work as a team and get hands on experience. Help other team members if they are facing difficulties in their part and to complete the assigned tasks on time to make this project a success.

Group Members and Responsibilities

Brain - Group Leader and Main Contact(Update: Resigned the course)

Brain will be in charge of organizing the project and distributing the workload of the project in a fair and even manner. Brain will distribute the work among the group members by their interests, strengths and weaknesses. Brain will be the in charge of outlining each part of the project and putting it up on wiki. The meeting timings will be set up by Brain considering the availability of other group members. Brain will also be helping out the group members of the project when help is required.

Tiffany - CAD Modeling Coordinator(Update: Resigned the course)

Tiffany will be in charge of the CAD modeling aspect of this project. Tiffany is good in CAD modeling and has some experience with it. She has access to a CAD modeling program. This helps our group look professional. Tiffany will also help other group members to accomplish their task in this project.

Tarandeep.S.Sodhi - Dissection and Reassembly Manager

Tarandeep will be responsible for the dissection and reassembly of this project. He will be responsible for taking down the notes and will create hand rough sketches when needed. He will know most of the dissection of this project. He will be helping out other group members to make this project a success.

Gantt Chart

Initial Product Assessment

The Ocean Wonders Mobile was developed by Fisher-Price for home use. Its many functions including ceiling projected light patterns, soothing lullabies and ocean sounds, and floating, rotating fish are designed to calm babies in their cribs as they go to sleep. It also features a remote control so that it can be turned on and off from a distance so the child is not disturbed or woken. Its adjustable pivoting swing arm allows for mounting anywhere from the rails of a crib, to a dresser top.

The remote control features a single on off button. It uses chemical energy from batteries which is converted to electrical energy. When the button is pressed a signal is emitted from the remote control by way of LED infrared pulses. A receiver built into the mobile component receives the pulses of light. The mobile component also runs off of chemical energy which is supplied by batteries, which is converted to electrical energy and used in various ways to run the different functions of the mobile. Some of the electrical energy is used to run a tiny motor which converts the electrical energy into mechanical energy in order to spin the head of the mobile and the hanging objects. Another portion of the electrical energy is converted into light energy in the upper portion of the head component to project the patterns onto the ceiling. The third use of the electrical energy is used to power the speaker which converts the energy into a rhythmic mechanical energy to produce sound waves.

The mobile appears to be in good working order; however a few tests should be run in order to confirm that it is running at its full potential.

Overall this mobile does not appear to be very complex. There are many functions that can be performed by the product, but the components that it uses are not to complex and are packed into a small product. The make up of the product is mostly plastic. The inner workings would be comprised of some small circuit boards, an infrared sensor, a small motor, some speakers, and small light bulbs.

The mobile is very user friendly. It has clearly marked switches to adjust the volume of the music and ocean sounds, brightness of the lights, and on/off switches. The remote control has one button simply used to turn the product on and off. The only maintenance required would be to replace the batteries in both the main unit and the remote control which each only require the removal of a couple phillips head screws for child safety purposes.

There are many different alternatives to this mobile made by Fischer-Price and many other companies. Many alternatives could be found at a cheaper price than this specific mobile. There are many benefits to this product including the ability to vary the sound an light intensity, and also the convenience of the remote control.

Gate - 2: Preliminary Design Review

Causes for Corrective Action

The work plan has been followed perfectly. By following these steps it gave us a good start for our disassembly plan, and made this project very manageable.

The management plan quite didn’t work for our group as we decided on. The members assigned to do work didn’t finish it on-time due to lack of communication. And the end result of it was that it became an individual project from a group project as the members of the group resigned this course.

But, I am ready to take up all the challenges and duties required to finish this project.

Product Dissection Plan

The product for this project is Fisher Price Children’s toy - Ocean Wonders Mobile with Remote Control. It is a very reliable product which fulfills all the needs of the customer. This product is made under lots of engineering analysis such as, stress and strain calculations on the arm which supports the weight of the hub. It is build to be a very sturdy toy; to make sure that all the parts in the product remain in place and do not cause a safety hazard. But, it is fairly easy to disassemble it. We rated it a 7 out of 10 on the complexity of disassembly, 1 being the easiest and 10 being the hardest.

In our work proposal we have stated the tools we would require to disassemble the product are:

Disassembly Procedures

Scale for ease of assembly: All values given in comparison to all of the other steps of taking this mobile toy apart. This is with a “1” being a simple task such as unscrewing something and a “5” being taking apart a piece that is breakable and not easy to get at without care.

1. Detach the base from the arm.Level of Difficulty: 1

2. Unscrewed the battery cover from the backside of the Base.Level of Difficulty: 1

3. Removed the four D-size batteries from the base.Level of Difficulty: 1

4. With the help of a small black stick, we were able to take out the back casing of the base.Level of Difficulty: 1

5. Removed five screws from the inside of the cover of the base, which helped in detaching the outer blue ring which was attached to the front side of the base.Level of Difficulty: 1

6. Removed the plastic decoration from the face of the base.Level of Difficulty: 1

7. Removed three screws from the hub to disassemble the three soft toy spokes.Level of Difficulty: 1

8. Removed the screws from the bottom of the hub, which helped us in disassembling the top cover of the hub, the buttons and the top light cover of the hub.Level of Difficulty: 1

9. Disassembled the light cover from the hub.Level of Difficulty: 1

10. Took apart the big gear attached at the bottom of the light cover.Level of Difficulty: 1

11. Took apart the design molding inside the light cover.Level of Difficulty: 1

12. Removed the screws to disassemble the circuit board cover.Level of Difficulty: 1

13. Detached the circuit board from the hub.Level of Difficulty: 1

14. Disassembled a socket from the hub machine cover.Level of Difficulty: 1

15. Detached the power supplying wires attached to the arm.Level of Difficulty: 1

16. Detached the arm from the hub (snap socket).Level of Difficulty: 4

17. Disassembled the speaker cover attached to the hub base.Level of Difficulty: 1

18. Disassembled the speaker from the hub base.Level of Difficulty: 1

19. Disassembled the buttons and the electric circuit board from the hub base.Level of Difficulty: 1

20. Removed the rubber belt from the small pulley, which is attached to the motor inside the hub.Level of Difficulty: 1

21. Took apart the big pulley attached to the small pulley from the motor cover attached inside the hub.Level of Difficulty: 1

22. Removed the small gear socket attached to the gear train under the motor cover.Level of Difficulty: 1

23. Took apart the motor cover from the hub.Level of Difficulty: 1

24. Took apart the motor bushing attached to the motor cover/board.Level of Difficulty: 1

25. Took apart the motor from the hub base.Level of Difficulty: 1

26. Took apart the first gear from the gear train attached to the base of the hub.Level of Difficulty: 1

27. Disassembled the second gear from the gear train attached to the base of the hub.Level of Difficulty: 1

28. Removed two screws to disassemble the hub base from the bottom hub light cover.Level of Difficulty: 1

29. Removed a screw attached to the hub base to remove the third gear from the gear train. A small thick gear was attached to the outer bottom of the hub cover and the third big gear was inside the hub cover.Level of Difficulty: 1

30. Disassembled the light snap cover from the outer surface of the hub cover.Level of Difficulty: 1

31. Took apart the light with wire attached from the bottom hub cover.Level of Difficulty: 1

32. Took apart the top light case from the circuit board cover.Level of Difficulty: 1

33. Disassembled the small gear attached on top of the circuit board cover.Level of Difficulty: 1

Disassembly procedure of a Remote

2. Removed the battery cover by pulling it upwards.Level of Difficulty: 1

3. Removed the AA-batteries from the remote.Level of Difficulty: 1

4. Unscrew the three screws at the backside of the remote control.Level of Difficulty: 1

5. Pull out the bottom base.Level of Difficulty: 1

6. Pull out the green band attached to the top cover of the remote.Level of Difficulty: 1

7. Detach the yellow button attached to the top cover of the remote.Level of Difficulty: 1

8. Pull out the red signal cover from the bottom cover of the remote.Level of Difficulty: 1

Total Time taken to disassemble the product was 2.5 hours.

If you faced challenges during dissection outline those challenges and describe how they were overcome.

There were few problems encounters during the whole process of disassembly:

1. All the wires were soldered to the circuit board located inside the hub. Therefore the disassembly of the hub was done very carefully and with right wire management.
2. The arm of the product can’t be disassembled as the plastic joint is factory glued and there is lot of chances of breaking it if forced. So the arm was not disassembled (opened).

Is the product intended to be taken apart easily?

Yes, the product was intended to be taken apart easily. Some, of the parts come disassembled and they are assembled by the user when first bought such as the arm to the hub, spokes which snaps to the hub and the base to the arm.

Special tool required to disassemble the product was the long nose plier which helped in removing the arm from the hub.

GATE - 3: Coordination Review

Causes for Corrective Action

As of now all my other two group members have resigned this course. I am trying to be on schedule as it is almost the end of the semester and I am doing this whole project by my own. I might be slightly behind than the other groups in my class, but I am doing the best of my ability to carry it by my own.

The prediction of disassembling of Ocean Wonder would take about two hours, but when I started dissemble it ,it took me more than 2 and a half hours. That was caused by the some unexpected problems during the whole process. The structure of the machine looked really simple and a fun job to do. But as I proceeded with the process, complexion stood in front of me. My misconception of simple changed to a hardworking job as it had more parts as I expected when I saw it .But I was lucky in some of the assumptions I made about the fact that the machine is not supposed to be apart as there was the circuit board and the components were soldered to it. There were other minor difficulties I faced that were disengaging the plastic parts such as spokes from the night light cover and arm from the rub.

Coordination Review

The main purpose of the coordination review is to analyze the components of Ocean Wonders mobile with remote Control (Mobile). In order to see what mechanism works well, and what can be improved in other forms of analysis for better understanding of the toy. The Component Summary lists all the components of the mobile of the mobile toy , including what material is used and what manufacturing process has been used to manufacture each component .The component summary reflection further discusses what was found inside the Ocean Wonder Mobile. Using these components, solid model can be made to show how part of this mobile toy works or assembled in sequence design revisions can be made based on total analysis of the product. Finally, Engineering Analysis can be used in order to show how further analysis and testing can be done on Ocean Wonders Mobile.

Component Summary

After disassembly of the product 60 components were found which were used to build this whole product. The components of this product are listed in the table below.

Most of the components inside the product was made out of plastic .The housing of the< hub, base and aim was much harder and stable. It seems to be PVC. Plastic was chosen because. It is cheap, available easily and makes the products weight lighter.

What forces are applied to the components?

In my product there is a gravitational force acting downward on the hub due to its weight the force is supported by the arm and the base.

Does the material choice affect the manufacturing process?

The prevalence of plastic material in the Mobile toy makes the process much easier and cost effective. There were many places in which pieces snapped into places, which is much easier to accomplish with plastic components than it is with metal. This also made the assembly process of the product much quicker.

Does the shape affect the manufacturing process?

Injection molding was used for all of the plastic components, such as gears, clutch plates, hub, base, arm etc. because of their complicated shapes and for a better finish with a precise configuration.

Machining: Can produce complicated shapes with high precision for metal pieces.

Coiling: Right way to manufacture springs. </p>

Does any component have a particular shape? Why?

Every component has a distinct shape that allows them to fulfill their purpose .All the edges in the product are rounded, so that the child won’t get hurt. Some of them screws are washer headed because the spoke hole was little wider than the hub hole, where it was attached.

Is the component functional, cosmetic or, a combination of two?

There are few components used in our product which are cosmetic, such as the plastic decoration in front of the base. There are some components which are cosmetic as well as functional such as the decorative mold placed inside the light dome which is connected to the clutch plate. It projects the decorations made on the mold on the room’s roof when the product is functional.

Why do you think the manufacturing process was chosen for a given component?

To make the product cost efficient, produce it in a large quantities, little waste of material and for a better finish with in the given time.

How complex is the component?

Complexity of the components of the product can be ranked on a scale of 1 to 5.

1. Solid component made up of one material with a simple shape for example pulley, gear, and clutch plates.
2. Components made up of one material with a complex shape for example base, hub housing etc
3. Components made up of two different materials example springs
4. Components made up of two materials with complex shapes example arm
5. Electric Components such as circuit boards and motor

Design Revisions

• According to the users the crib adapter doesn’t fit in all the cribs, so we can make a new interchangeable crib adapter which can fit in all cribs.
• We can also add some more additional themes to this product such as animals, angles etc., which gives user a wide range of selection.
• Adding musical button feature at base of the product, which makes different sound (related to the theme) every time when the buttons are pressed. This will add little bit more functionality to the base as well as the whole products.

Engineering Analysis

Problem Statement: Calculate the forces acting on gear three.

Assumptions:

1. Assume that no external force is acting on the system.
2. Pinion two runs at 10 rev/min.
3. It transmits 5 W to ideal gear three.
4. Teeth of the gears are cut on 20 degrees full depth.
5. Have a module of M = 2.5mm.
6. Gear three is a idler it transmits no power to its shaft. Therefore, the tangential reaction of gear four and three is equal to Wt (transmitted load, lbf).

Solid Model

Gate # 4: Critical Project Review

The critical project review is to provide a final review of the Ocean Mobile and its components before final submission of the project .It also provides a step by step procedure for reassembling the ocean wonder mobile .Later in this section we will also discuss the differences between the two procedures (disassembly and reassembly).We will also discuss how well the product works after reassembly, if it doesn’t work then what went wrong and how the problem can be fixed.

Product Reassembly Plan

The reassembly of the Oceanic wonder mobile took two hours approximately .Each step required to reassemble the product is detailed below:

Reassembly Procedure:

Scale for ease of assembly: All values given in comparison to all of the other steps of putting this mobile toy together. This is with a “1” being a simple task such as screwing something together and a “5” being reassembling a piece that is breakable and not easy to put together without care.

Step#

Process

Difficulty Level

1

Put the screw back to the hub base to attach the third gear of the gear train. A small thick gear is attached to the outer bottom of the hub cover and the third cover inside the hub cover.

1

2

Screw in two screws to reassemble the hub base to the bottom hub light cover.

1

3

Reassembled the second gear to the gear train, which is then attached to base of the hub.

1

4

Reassembled the first gear to the gear train which is then attached to the base of the hub.

1

5

Put back the motor into the hub base.

2

6

Put back the motor bushing so that it is attached to the motor cover / board.

1

7

Put back the motor cover back on the hub.

1

8

Attach the small gear which connects to the gear train located under the motor cover.

2

9

Put back the big pulley on top of the motor cover and connect to the gear train

1

10

Connect the big pulley to the small pulley attached on top of the motor with the help of a rubber belt.

4

11

Reassembled the circuit board and the buttons back on the hub base.

1

12

Put the speaker back in to the slot made in the hub case.

1

13

Screw the speaker cover back to the hub base.

1

14

Put the power supply wires/spring connections back to their position on the hub.

3

15

Reassemble the socket back on to the hub machine cover.

1

16

Screw back the circuit board back on the hub.

1

17

Put back the design molding inside the light cover.

1

18

Attach the clutch plate back at the bottom of the light cover

2

19

Reassembled the light cover back on the hub

2

20

Put the screws back into the bottom of the hub, which helped in reconnecting the top cover of the hub, the buttons and the top light cover of the hub.

1

21

Attached the three soft toy spokes back together with help of the screws

1

22

Put back the plastic decoration back on to the front side of the base.

1

23

Attached the blue ring in front of the base with the help of five reasons.

Tools required reassembling the product:

Yes, The Oceanic wonder Mobile functions the same as it was before it was disassembled .The product was picked up in perfect working condition; It is still working the same way with no problems.

What were the differences between the disassembly/reassembly of the product?

The process of assembly is almost the reverse of the disassembly. The only difference in assembly is that the aim connects to the hub and the base at the last, whereas during disassembly. I was not able to separate to separate the hub from the arm as it was snapped into the hub. Same set of tools were used again to reassemble the whole product.

Additional recommendations:

Additional feature for tor the Ocean Wonder Mobile would be to add a rechargeable battery to the base instead of 4-D alkaline batteries .The disadvantage of this will be a little hike in the price but it would be out-weighted by increase in the life of the product and the cost of spending money on the four D alkaline batteries will be gone.